ZF 5HP19 transmission repair manual

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REPAIR-MANUAL
5 HP - 19
ZF GETRIEBE GMBH SAARBRUCKEN
Version 99/04/15

Subject to alterations
(c) Copyright 1998, all rights reserved. Published by
ZF Getriebe GmbH, Saarbrucken, Department MKTD
No part of this manual may be repoduced or transmitted in any form
or by any means, electronic or mechanical, including photocopying and recording,
for any purpose without the express written permission of
ZF Getriebe GmbH, Saarbrucken
Printed in Germany

Contents
Page
Preliminary information
ii
1.
General information
1.1/1
1.1
Picture of the transmission
1.1/1
1.2
Power flow diagram
1.2/1
1.3
Specifications
1.3/1
1.3.1
Screw torque specifications
1.3/1
1.3.1.1 Pump
1.3/1
1.3.1.2 Cylinder DG
1.3/1
1.4
Making adjustments
1.4/1
1.4.0
Preparing the clearance measurement tool
1.4/1
1.4.1
Adjusting clearance of brake F
(snap ring)
1.4/3
1.4.2
Adjusting clearance of brake D
(snap ring)
1.4/5
1.4.3
Adjusting clearance of brake G
(snap ring)
1.4/7
1.4.4
Adjusting clearance of brake E
(snap ring)
1.4/9
1.4.5
Adjusting clearance of clutch A
(snap ring)
1.4/11
1.4.6
Adjusting clearance of clutch B
(snap ring)
1.4/13
1.4.7
Adjusting clearance of brake C
(snap ring)
1.4/15
1.4.8
Output play
(shim)
1.4.17
1.4.9
Input play
(shim)
1.4.19
1.4.10
Adjusting the switch
(detent spring)
1.4.21
1.5
Tightening torques
1.5/1
1.6
Transmission test (test bench/vehicle)
1.6/1
1.7
Special tools
1.7/1
2.
Removing assemblies
2.1/1
2.1
Removing the converter, oil pan and automatic control unit
2.1/1
2.2
Removing the oil supply
2.2/1
2.3
Removing the input assembly
2.3/1
2.4
Removing the tower
2.4/1
2.5
Removing the output assembly
2.5/1
Disassembly
2.6
Output assembly
2.6/1
2.7
Tower
2.7/1
2.7.1
Planetary drive
2.7/1
2.7.2
Clutch F
2.7/4
2.7.3
Brake D/G
2.7/5
2.8
Input assembly
2.8/1
2.8.1
Clutch E
2.8/2
2.8.2
Clutch A
2.8/3
2.8.3
Clutch B
2.8/4
2.9
Oil supply with brake C
2.9/1
2.9.1
Brake C
2.9/1
2.9.2
Pump
2.9/2
99/04/15
5 HP 19 (c) ZF Getriebe GmbH Saarbrucken
CD
I

3.
Assembly
3.1/1
3.1
Housing with selector mechanism and parking lock
3.1/1
3.2
Tower
3.2/1
3.2.1
Planetary drive
3.2/1
3.2.2
Clutch F
3.2/4
3.2.3
Brake DG with freewheel, 1st gear
3.2/6
3.3
Output assembly
3.3/1
3.4
Planetary drives I and II
3.4/1
3.5
Input assembly (with clutches A and B)
3.5/1
3.5.1
Clutch E (input)
3.5/1
3.5.2
Clutch A (input)
3.5/4
3.5.3
Clutch B (input)
3.5/7
3.6
Oil supply with brake C
3.6/1
3.7
Input assembly with oil supply
3.7/1
3.8
Automatic control unit, flow control valve, oil filter and oil pan
3.8/1
3.9
Position switch and converter
3.9/1
II
CD
5 HP 19 (c) ZF Getriebe GmbH Saarbrucken 99/04/15

Preliminary information
This manual covers the procedure for repairing the complete transmission.
Repairs to this transmission must be carried out by persons trained by ZF Getriebe GmbH.
All disassembly and re-assembly work should be carried out in the order described.
The photographs apply to various versions and have therefore been kept general. They are not bin-
ding in every case.
Important changes that are specific to particular applications and need to be taken into account
when carrying out repair work are announced in Service Bulletins and training courses.
If this repair manual is given to a third party, it will not be covered by our alteration service.
The instructions and specifications given in the Service Bulletins must be followed when carrying
out repairs.
Depending on the damage that has occurred, it may be possible to limit repair work to this dama-
ge.
The following points should be noted:
* Seals, e.g. O-rings, shaft seals, gaskets and filters, should always be renewed.
* All O-rings, rectangular-section rings and other sealing rings should be smeared with
white petroleum jelly before being fitted.
* All bearings must be fitted in a lightly oiled condition.
* All lined clutch discs and steel discs on high-mileage transmissions ( > 80,000 km) must
be replaced.
* Following damage to clutches/brakes, the converter, oil tubes and oil cooler must be
thoroughly and adequately cleaned with a suitable cleaning agent.
Before carrying out repair work, make sure that:
* All special tools required are readily available.
The complete set of special tools is listed in Chapter 1.8.
* A suitable transmission test bench is available.
See Service Bulletins for the required test values.
99/04/15
5 HP 19 (c) ZF Getriebe GmbH Saarbrucken
CD
III

Please note:
In this manual, the automatic control unit is treated as a complete unit. It should not be disassem-
bled except by a specialist. It should be exchanged as a complete unit.
A separate manual is planned for the automatic control unit.
Important:
The transmission is filled with a long-life oil.
The oil does not have to be changed until it has been in use for 10 years.
The transmission must be delivered with the volume and type of oil specified in the relevant parts
list documentation (see ELCAT).
Otherwise, the transmission may fail.
Techn. After Sales Service
Techn. Documentation
After Sales Service School
Bach
Reus
Schultz
IV
CD
5 HP 19 (c) ZF Getriebe GmbH Saarbrucken 99/04/15

1.
General information
1.1
Picture of the transmission
99/04/15
5 HP 19 (c) ZF Getriebe GmbH Saarbrucken
CD
1.1/1


1.2 Power flow diagram
1. Gear
2. Gear
3. Gear
4. Gear
5. Gear
Reverse Gear
99/04/15
5 HP 19 (c) ZF Getriebe GmbH Saarbrucken
CD
1.2/1


Document Outline

  • Selection of language
  • Repair manual 5HP19
  • Contents
    • 1. General information
      • 1.1 Picture of the transmission
      • 1.2 Power flow diagram
      • 1.3 Specifications
        • 1.3.1 Screw torque specifications
          • 1.3.1.1 Pump
          • 1.3.1.2 Cylinder DG
      • 1.4 Making adjustments
        • 1.4.0 Preparing the clearance measurement tool
        • 1.4.1 Adjusting clearance of brake F (snap ring)
        • 1.4.2 Adjusting clearance of brake D (snap ring)
        • 1.4.3 Adjusting clearance of brake G (snap ring)
        • 1.4.4 Adjusting clearance of brake E (snap ring)
        • 1.4.5 Adjusting clearance of clutch A (snap ring)
        • 1.4.6 Adjusting clearance of clutch B (snap ring)
        • 1.4.7 Adjusting clearance of brake C (snap ring)
        • 1.4.8 Output play (shim)
        • 1.4.9 Input play (shim)
        • 1.4.10 Adjusting the switch (detent spring)
      • 1.5 Tightening torques
      • 1.6 Transmission test (test bench/vehicle)
      • 1.7 Special tools
    • 2. Removing assemblies
      • 2.1 Removing the converter, oil pan and automatic control unit
      • 2.2 Removing the oil supply
      • 2.3 Removing the input assembly
      • 2.4 Removing the tower
      • 2.5 Removing the output assembly
      • Disassembly
      • 2.6 Output assembly
      • 2.7 Tower
        • 2.7.1 Planetary drive
        • 2.7.2 Clutch F
        • 2.7.3 Brake D/G
      • 2.8 Input assembly
        • 2.8.1 Clutch E
        • 2.8.2 Clutch A
        • 2.8.3 Clutch B
      • 2.9 Oil supply with brake C
        • 2.9.1 Brake C
        • 2.9.2 Pump
    • 3. Assembly
      • 3.1 Housing with selector mechanism and parking lock
      • 3.2 Tower
        • 3.2.1 Planetary drive
        • 3.2.2 Clutch F
        • 3.2.3 Brake DG with freewheel, 1st gear
      • 3.3 Output assembly
      • 3.4 Planetary drives I and II
      • 3.5 Input assembly (with clutches A and B)
        • 3.5.1 Clutch E (input)
        • 3.5.2 Clutch A (input)
        • 3.5.3 Clutch B (input)
      • 3.6 Oil supply with brake C
      • 3.7 Input assembly with oil supply
      • 3.8 Automatic control unit, flow control valve, oil filter and oil pan
      • 3.9 Position switch and converter